Method and apparatus for preparing microparticles using in-line solvent extraction

ABSTRACT

Apparatus and method for preparing microparticles using in-line solvent extraction. An emulsion is formed by combining two phases in a static mixer. The emulsion is combined with an extraction liquid in a blending static mixer. The outflow of the blending static mixer is combined with additional extraction liquid. The additional extraction liquid and the outflow of the blending static mixer can be combined in a vessel, or through the use of a static mixer manifold that includes a plurality of static mixers.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of Ser. No. 09/930,450 filed Aug. 16,2001, now U.S. Pat. No. 6,540,393 which is a divisional application ofSer. No. 09/438,656 filed Nov. 12, 1999, now U.S. Pat. No. 6,495,166.

This application is related to application Ser. No. 09/438,659, filedNov. 12, 1999, application Ser. No. 09/828,849, filed Apr. 10, 2001, andapplication Ser. No. 10/109,641, filed Apr. 1, 2002, the entirety ofeach of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to preparation of microparticles. Moreparticularly, the present invention relates to a method and an apparatusfor preparing microparticles using in-line solvent extraction.

2. Related Art

A variety of methods is known by which compounds can be encapsulated inthe form of microparticles. It is particularly advantageous toencapsulate a biologically active or pharmaceutically active agentwithin a biocompatible, biodegradable wall forming material (e.g., apolymer) to provide sustained or delayed release of drugs or otheractive agents. In these methods, the material to be encapsulated (drugsor other active agents) is generally dissolved, dispersed, oremulsified, using stirrers, agitators, or other dynamic mixingtechniques, in a solvent containing the wall forming material. Solventis then removed from the microparticles and thereafter the microparticleproduct is obtained.

Development of a microencapsulation process suitable for commercialscale production typically requires scaling up, by multiple factors, alaboratory scale process and/or a pilot scale process. The scaled-upprocess will almost always require larger piping and higher flow rates,particularly when the scale factor is very large or if it is desired ornecessary to keep process transfer times similar to the smaller scaleprocesses. Scale-up into new, larger equipment is often unpredicatableand achieved in large measure through trial and error. However, theeconomic costs of large-scale trial and error experiments can beprohibitive.

One approach to aiding the scale-up process is to use a static mixer toform an emulsion, as disclosed in U.S. Pat. No. 5,654,008. In the methoddisclosed in U.S. Pat. No. 5,654,008, a first phase, comprising theactive agent and the polymer, and a second phase are pumped through astatic mixer into a quench liquid to form microparticles containing theactive agent. The use of a static mixer to form the emulsion tends tomake the scale-up more predictable and reliable than the scale-up ofother dynamic-mixing processes for making microparticles. However,numerous trials and experiments are still required to completely andaccurately scale-up, such as to commercial scale or by a factor of 20 ormore, a process such as the one disclosed in U.S. Pat. No. 5,654,008.

Thus, there is a need in the art for an improved method and apparatusfor preparing microparticles. There is a particular need in the art foran improved process that can be more quickly, reliably, and accuratelyscaled-up from a laboratory or pilot scale to a commercial scale. Thepresent invention, the description of which is fully set forth below,solves the need in the art for such a method and apparatus.

SUMMARY OF THE INVENTION

The present invention relates to an apparatus and method for preparingmicroparticles. In one aspect of the invention, a method of preparingmicroparticles is provided. The method comprises:

preparing a first phase, the first phase comprising an active agent anda polymer;

preparing a second phase;

combining the first phase and the second phase in a first static mixerto form an emulsion;

combining the emulsion and a first extraction liquid in a second staticmixer; and

combining an outflow of the second static mixer with a second extractionliquid.

In one aspect of such a method, the outflow of the second static mixerflows into a vessel containing the second extraction liquid. In anotheraspect, the outflow of the second static mixer flows into a vessel, andthe second extraction liquid is added to the vessel. The secondextraction liquid can be added to the vessel either while the outflow ofthe second static mixer is flowing into the vessel, or after the outflowof the second static mixer has completed flowing into the vessel. In yetanother aspect, the outflow of the second static mixer and the secondextraction liquid can be combined in another static mixer.

In a further aspect of the present invention, another method forpreparing microparticles is provided. The method comprises:

preparing a first phase, the first phase comprising an active agent anda polymer;

preparing a second phase;

combining the first phase and the second phase in a first static mixerto form an emulsion, the emulsion forming an outflow of the first staticmixer;

combining the outflow of the first static mixer and a first portion of astarting volume of an extraction liquid in a second static mixer to forman outflow of the second static mixer;

dividing the outflow of the second static mixer to form at least twoflow streams;

flowing each of the at least two flow streams through a separate thirdstatic mixer; and

combining the at least two flow streams with a second portion of theextraction liquid.

In one aspect of such a method, the at least two flow streams flow intoa vessel containing the second portion of the extraction liquid. Inanother aspect, the at least two flow streams and the second portion ofthe extraction liquid are combined in a fourth static mixer. In yetanother aspect, the at least two flow streams and the second portion ofthe extraction liquid are combined in a fourth static mixer, and thecombining step is repeated until the starting volume of the extractionliquid is depleted. The combining step may be repeated by continuing tocombine the at least two flow streams and the extraction liquid in thefourth static mixer until the starting volume of the extraction liquidis depleted. Alternatively, the combining step may be repeated bycombining the at least two flow streams and the extraction liquid inadditional static mixers until the starting volume of the extractionliquid is depleted.

In a further aspect of the present invention, another method forpreparing microparticles is provided. The method comprises:

preparing a first phase, the first phase comprising an active agent anda polymer;

preparing a second phase;

combining the first phase and the second phase in a first static mixerto form an emulsion, the emulsion forming an outflow of the first staticmixer;

combining the outflow of the first static mixer and a first extractionliquid in a second static mixer to form an outflow of the second staticmixer;

dividing the outflow of the second static mixer to form at least twoflow streams;

flowing each of the at least two flow streams through a separate thirdstatic mixer; and

combining the at least two flow streams with a second extraction liquid.

In yet a further aspect of the present invention, a microencapsulatedactive agent prepared by a method for preparing microparticles isprovided. Such a method comprises:

preparing a first phase, the first phase comprising an active agent anda polymer;

preparing a second phase;

combining the first phase and the second phase in a first static mixerto form an emulsion;

combining the emulsion and a first extraction liquid in a second staticmixer; and

combining an outflow of the second static mixer with a second extractionliquid.

In yet a further aspect of the present invention, a microencapsulatedactive agent prepared by another method for preparing microparticles isprovided. Such a method comprises:

preparing a first phase, the first phase comprising an active agent anda polymer;

preparing a second phase;

combining the first phase and the second phase in a first static mixerto form an emulsion, the emulsion forming an outflow of the first staticmixer;

combining the outflow of the first static mixer and a first portion of astarting volume of an extraction liquid in a second static mixer to forman outflow of the second static mixer;

dividing the outflow of the second static mixer to form at least twoflow streams;

flowing each of the at least two flow streams through a separate thirdstatic mixer; and

combining the at least two flow streams with a second portion of theextraction liquid.

In still a further aspect of the present invention, a system forpreparing microparticles is provided. The system includes a first andsecond pump, and a first static mixer in fluid communication with eachof the pumps. One of the pumps is configured to pump an organic phaseinto the first static mixer. One of the pumps is configured to pump acontinuous phase into the first static mixer. A manifold, comprising aplurality of static mixers, is in fluid communication with the firststatic mixer. A third pump, in fluid communication with the manifold, isconfigured to pump an extraction liquid. A second static mixer is influid communication with the manifold. An outflow of the first staticmixer and the extraction liquid flow through the manifold and thenthrough the second static mixer.

In another aspect, the system can include a third static mixer in fluidcommunication with the first static mixer and with the manifold. Theoutflow of the first static mixer and the extraction liquid are combinedin the third static mixer, prior to flowing through the manifold. Thesystem may also include a vessel in fluid communication with the secondstatic mixer so that an outflow of the second static mixer flows intothe vessel. A fourth pump may also be provided to pump the extractionliquid into the second static mixer.

Features and Advantages

It is a feature of the present invention that it can be used to preparemicroparticles, including microparticles containing an active agent.

It is another feature of the present invention that it allows forparallel flow streams for the in-line solvent extraction.

Yet another feature of the present invention is the ability to easilyuse different extraction liquids during the process. The system can beconfigured to introduce such different extraction liquids at theappropriate time and processing point.

An advantage of the present invention is that it substantially reducesor eliminates the need for a separate quench or extraction tank thatcontains a large volume of quench liquid, to remove solvent, and to formhardened microparticles.

The present invention advantageously enables the controlled extractionof the polymer solvent from a polymer/active agent droplet to formmicroparticles containing the active agent. The process advantageouslyprovides a level of solvent removal sufficient for commercial products.The process also advantageously provides high loading efficiency, makingit particularly useful for commercial products.

The process of the present invention advantageously provides a moreconsistent processing environment than conventional processes forforming microparticles. The in-line solvent extraction method of thepresent invention allows the emulsion droplets to all be exposed to thesame processing conditions. In contrast, in conventional processes usingan extraction tank or vessel, the processing conditions change over timeas the solvent is extracted from the emulsion droplets in the tank.

The consistent processing conditions and environment of the presentinvention advantageously result in a process that is less time-dependentor scale-dependent than alternative processes.

The present invention provides a method and apparatus that areparticularly advantageous for scale-up. The parallel path manifold ofthe present invention allows for capacity increases from an established(single path) system without full-scale trial and error experiments innew and different equipment. The total flow rate can be increased fromthe single path system based upon the number of flow streams in themanifold.

BRIEF DESCRIPTION OF THE FIGURES

The present invention is described with reference to the accompanyingdrawings. In the drawings, like reference numbers indicate identical orfunctionally similar elements.

FIG. 1 shows one embodiment of an equipment configuration for preparingmicroparticles in accordance with the present invention;

FIG. 2 shows another embodiment of an equipment configuration forpreparing microparticles in accordance with the present invention;

FIG. 3 illustrates flow through a static mixer; and

FIG. 4 shows a static mixer suitable for use with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Overview

The present invention provides an improved method and apparatus forpreparing microparticles. The apparatus and methods of the presentinvention use in-line solvent extraction to provide a process that ismore scalable, with less overall processing time, than conventionalmethods.

The methods of the present invention use a static mixer to combine afirst phase, comprising an active agent and a polymer, with a secondphase to form an emulsion. A process for forming an emulsion using astatic mixer is described, for example, in U.S. Pat. No. 5,654,008, theentirety of which is incorporated herein by reference. The phasecomprising the active agent and the polymer may be referred to herein asthe “organic phase”. The other phase may be referred to herein as the“continuous phase”.

The outflow of the static mixer in which the emulsion is formed iscombined with an extraction liquid in another static mixer that may bereferred to herein as a “blending static mixer”. In one embodiment, theoutflow of the blending static mixer flows into a vessel where it iscombined with additional extraction liquid that may be the same ordifferent from the extraction liquid added to the blending static mixer.In another embodiment, the outflow of the blending static mixer isdivided into a plurality of flow streams that flow through a manifoldcontaining a plurality of static mixers. The plurality of flow streamsare recombined downstream, and combined with additional extractionliquid. In a particularly preferred embodiment, the recombined flowstreams and the additional extraction liquid are combined in anotherstatic mixer, and this combining step is repeated until the startingvolume of the extraction liquid is depleted. Such an embodimenteliminates the need for an extraction tank for extracting solvent.

In the present invention a blending static mixer is used to combine theemulsion and the extraction liquid to form a combined flow stream. Inone embodiment, the combined flow stream is divided into a plurality offlow streams for flow through the manifold. The use of the blendingstatic mixer prior to the manifold is particularly advantageous becausethe emulsion and the extraction liquid may not be immediately miscibleor homogeneous, making the division of the combined flow streamproblematic. For multiphase streams such as the combined emulsion andextraction liquid, the use of the manifold without the blending staticmixer could result in different compositions in each static mixer in themanifold. Because the combined emulsion and extraction liquid is nothomogeneous, it would not divide evenly in conventional piping.

The manifold configuration of the present invention is particularlyadvantageous for scale-up. The parallel path manifold of the smallerdiameter static mixers allows for capacity increases from an established(single path) system without full-scale trial and error experiments innew and different equipment. The total flow rate can be increased fromthe single path system based upon the number of flow streams in themanifold.

To ensure clarity of the description that follows, the followingdefinitions are provided. By “microparticles” or “microspheres” is meantsolid particles that contain an active agent or other substancedispersed or dissolved within a polymer that serves as a matrix orbinder of the particle. The polymer is preferably biodegradable andbiocompatible. By “biodegradable” is meant a material that shoulddegrade by bodily processes to products readily disposable by the bodyand should not accumulate in the body. The products of thebiodegradation should also be biocompatible with the body. By“biocompatible” is meant not toxic to the body, is pharmaceuticallyacceptable, is not carcinogenic, and does not significantly induceinflammation in body tissues. As used herein, “body” preferably refersto the human body, but it should be understood that body can also referto a non-human animal body. By “weight %” or “% by weight” is meantparts by weight per total weight of microparticle. For example, 10 wt. %active agent would mean 10 parts active agent by weight and 90 partspolymer by weight. Unless otherwise indicated to the contrary,percentages (%) reported herein are by weight. By “controlled releasemicroparticle” or “sustained release microparticle” is meant amicroparticle from which an active agent or other type of substance isreleased as a function of time. By “mass median diameter” is meant thediameter at which half of the distribution (volume percent) has a largerdiameter and half has a smaller diameter.

METHOD AND EXAMPLES

The following examples are provided to explain the invention, and todescribe the materials and methods used in carrying out the invention.The examples are not intended to limit the invention in any manner.

Example 1 Preparation of Risperidone Microparticles

Microparticles comprising risperidone were prepared at the one-kilogramscale. The 1 Kg process (400 grams of active agent and 600 grams ofpolymer) provides a theoretical drug loading of the microparticles of40% (400 grams/1000 grams×100%).

A 16.7% polymer solution was prepared by dissolving 600 grams ofMEDISORB® 7525 DL polymer (Alkermes, Inc., Blue Ash, Ohio) in ethylacetate. A 24% drug solution was prepared by dissolving 400 grams ofrisperidone base (Janssen Pharmaceutica, Beerse, Belgium) in benzylalcohol. The organic phase was prepared by mixing the drug solution intothe polymer solution. The continuous or aqueous phase was 30 Kg of a 1%polyvinyl alcohol (PVA) solution containing 6.5% ethyl acetate.

The emulsification step used two positive displacement pumps that fedthe individual phases (one pump for the organic phase and one pump forthe aqueous phase) to a connecting union where they were combined. A 5:1aqueous phase to organic phase ratio was maintained throughout theemulsification step, at an average total flow rate of 3.2 Kg/min.Immediately following the connecting union in the processing stream wasa ½ inch diameter in-line mixer, four feet in length. The exitingemulsion (outflow of the static mixer) was then mixed with an amount ofa first extraction solution that was pumped via a peristaltic pump at anaverage flow rate of 9 Kg/min. The total volume of the first extractionsolution that was transferred was 100 Kg.

The combined stream (diluted mixture of emulsion and first extractionsolution) was then passed through a 1-inch diameter in-line static mixer(blending static mixer) 16 inches in length. The mixture was then passedthrough approximately 56 inches of transfer piping to reach 144 Kg of asecond extraction solution contained in a stirred holding vessel. Themixture was stirred for 4 to 6 hours in the holding vessel. Samples wereperiodically taken to determine the levels of residual solvent(s), andto determine loading efficiency. Loading efficiency is the ratio,expressed as a percentage, of the actual drug loading to the theoreticaldrug loading.

Two experiments were done using the one-kilogram risperidone partialin-line extraction method described above. In Experiment One, the firstand second extraction solutions both contained 2.5% ethyl acetate. InExperiment Two, the first extraction solution contained 2.5% ethylacetate, and the second extraction solution was pure water.

The residual solvent levels and loading efficiencies obtained from thetwo experiments were compared to a control. The control was the averageof four one-kilogram batches of risperidone microparticles prepared inthe following manner. For each of the four control batches, the samesteps were used to prepare the organic and aqueous phases as in thepartial in-line extraction method described above, and the sameemulsification step was also used. However, for each of the four controlbatches, the emulsion exiting the first static mixer was thentransferred into a holding vessel that contained an aqueous extractionsolution containing 2.5% ethyl acetate.

A comparison of the results obtained in Experiments One and Two with therisperidone control is shown below in Table 1. Table 1 shows the levelof residual solvent for both ethyl acetate (Et/Ac) and benzyl alcohol(BA) for Experiments One and Two and the control. As shown in Table 1,the levels of residual solvent for Experiment One (3.6/5.1%) werecomparable to the levels of residual solvent for the risperidone control(3.0/5.0%). In Experiment Two, the residual BA solvent level (9.5%) wassignificantly higher than the risperidone control BA solvent level(5.0%). The rate of extraction of each solvent is affected by theconcentration of ethylacetate in the extraction solution, for example asdescribed in U.S. Pat. No. 5,650,173, the entirety of which isincorporated therein by reference. The results obtained in ExperimentTwo for the residual benzyl alcohol level of 9.5% were comparable,however, to another risperidone control processed without an initialethyl acetate component in the extraction solution, resulting in aresidual benzyl alcohol level in the microparticles of 9.3%. The lowerresidual solvent level of ethyl acetate in Experiment Two (0.9%) is alsolikely the result of the lack of ethyl acetate in the second extractionsolution.

TABLE 1 Risperidone Process Risperidone Partial In-Line ExtractionControl Experiment # One Two 1 kg Average Residual Solvents 3.6/5.1%0.9/9.5% 3.0/5.0% (EtAc/BA) Loading Efficiency 92.2% 88.0% 93.2%

As shown in Table 1, the loading efficiency of Experiment One (92.2%)was comparable to that of the risperidone control (93.2%). The 93.2%loading efficiency for the risperidone control is the loading efficiencyof the final microparticle product after the residual solvent levels ofethyl acetate and benzyl alcohol are reduced to 1-2%. Loading efficiencyfor the same product containing 5-9% residual solvent levels of ethylacetate and benzyl alcohol are expected to be lower due to mass balance.This is consistent with the results obtained in Experiment Two, with alower loading efficiency of 88.0%.

Example 2 Preparation of Bupivacaine Microparticles

Microparticles comprising bupivacaine were prepared at the twenty-gramscale. The 20 gram process (4 grams of active agent and 16 grams ofpolymer) provides a theoretical drug loading of the microparticles of20% (4 grams/20 grams×100%).

Sixteen grams of MEDISORB® 7525 DL polymer (Alkermes, Inc., Blue Ash,Ohio) and four grams of bupivacaine base were dissolved in 230 grams ofethyl acetate to make the organic phase. The aqueous phase consisted ofa 1% PVA solution containing a saturating amount of polymer solvent(ethyl acetate), with a pH of 8.5 and a trizma buffer concentration of0.05 molar. The extraction solution was a 0.05 molar trizma bufferedaqueous solution at a pH of 8.5

The emulsification step used two positive displacement pumps that fedthe individual phases (one pump for the organic phase and one pump forthe aqueous phase) to a connecting union where they were combined. Theorganic phase pump operated at 75 ml/min, and the aqueous phase pumpoperated at 150 ml/min. A 3:1 aqueous phase to organic phase ratio wasmaintained throughout the emulsification step. Immediately following theconnecting union was a ¼ inch diameter in-line static mixer, 17 and ½inches in length. The exiting emulsion (outflow of the static mixer) wasthen mixed with an amount of the extraction solution that was pumped viaa positive displacement pump at an extraction solution to emulsion ratioof 1:1. This extraction solution pump operated at 225 ml/min.

The combined stream (diluted mixture of emulsion and first extractionsolution) was then passed through a ⅜-inch diameter in-line static mixer(blending static mixer) 4 and ¾ inches in length. Even though extractionof solvents is occurring in the blending static mixer, at this point inthe process stream, the microdroplets of the emulsion have not fullyhardened, and further processing is needed to ensure desired particlesize. The outflow of the blending static mixer was divided into two flowstreams, each then passing through a separate individual ¼ inch diameterin-line static mixer 6 inches in length. The two flow streams createless shear in each flow stream, tending to create microparticles oflarger size. With only one large flow stream, there may be sufficientshear to result in smaller size microparticles. The two flow streamswere then recombined, and added to a flow stream of the extractionsolution that was pumped via a positive displacement pump operating at450 ml/min. The resulting flow stream was passed through a ½ inchdiameter in-line static mixer that was 12 inches in length, and thencollected in an initially empty holding vessel. The two extractionsolution pumps were started at the same time as the aqueous phase pump,and operated continuously.

After the organic phase had been exhausted, the contents in the holdingvessel were gently mixed via an overhead agitator and the remainingextraction solution was transferred to the holding vessel. The mixturewas agitated for an hour. The microparticles were recovered on a 25micron screen, dried in a hood overnight, and analyzed for residualsolvent level and loading efficiency.

The residual solvent level and loading efficiency obtained from the 20gram bupivacaine process were compared to a 20 gram bupivacaine control.The 20 gram bupivacaine control was made using the same aqueous,organic, and extraction solution, and concentrations thereof, as in thebupivacaine in-line extraction method described above. Theemulsification step was the same as described above, except for the useof a ¼ inch diameter, 16 inch long in-line static mixer to create theemulsion. The emulsion exiting this static mixer was then transferredinto the total volume of the extraction solution that was contained inthe stirred holding vessel.

A comparison of the results obtained using the bupivacaine in-lineextraction method (“bupivacaine process”) with the bupivacaine controlis shown below in Table 2. As shown in Table 2, the level of residualsolvent for the bupivacaine process is identical to the level ofresidual solvent for the bupivacaine control (4.2%). The loadingefficiency for the bupivacaine process (75%) is comparable to theloading efficiency for the bupivacaine control (88.5%).

TABLE 2 Bupivacaine Process In-Line Extraction Bupivacaine Control BatchSize 20 gram 20 gram Residual Solvent (EtAc) 4.2%  4.2% LoadingEfficiency  75% 88.5%

Examples 1 and 2 demonstrate that the process of the present inventionenables the controlled extraction of the polymer solvent from apolymer/active agent droplet to form microparticles containing theactive agent. Each of the emulsion droplets are exposed to substantiallythe same processing conditions throughout the process. The initialhardening of the emulsion droplets is not time or scale-dependent, as inconventional encapsulation processes. The process of the presentinvention provides a level of solvent removal sufficient for commercialproducts. The process also provides high loading efficiency, making itparticularly useful for commercial products.

Example 3 Methods for Preparing Microparticles

As exemplified by the examples discussed above, methods for preparingmicroparticles in accordance with the present invention will now bedescribed in more detail. Exemplary apparatus suitable for carrying outsuch methods will be described below. In one embodiment of the presentinvention, a first phase, comprising an active agent and a polymer, isprepared. In one embodiment of the present invention, the first phase isprepared by dissolving the active agent in a first solvent to form anactive agent solution. The polymer is dissolved in a second solvent toform a polymer solution. The active agent solution and the polymersolution are blended to form the first phase. In a particularlypreferred embodiment, the active agent is selected from the groupconsisting of risperidone, 9-hydroxyrisperidone, and pharmaceuticallyacceptable salts thereof. In such an embodiment, a preferred firstsolvent is benzyl alcohol, and a preferred second solvent is ethylacetate.

In another embodiment of the present invention, the first phase isprepared by dissolving the active agent and the polymer in a solvent toform a solution. In a particularly preferred embodiment, the activeagent is bupivacaine, and the solvent is ethyl acetate. It should beunderstood that the present invention is not limited to any particularmethod or process by which the first phase is prepared, and othersuitable processes would be readily apparent to one skilled in the art.

A second phase is prepared, and combined with the first phase in a firststatic mixer to form an emulsion. In a preferred embodiment, the twophases are pumped into the static mixer, with the second phase beingpumped at a flow rate greater than the flow rate of the first phase. Inone preferred embodiment, the ratio of the flow rate of the second phaseto the flow rate of the first phase is approximately 2:1. Exemplaryratios of the volume of the second phase to the volume of the firstphase are approximately 5:1 and approximately 3:1. However, it should beunderstood by one skilled in the art that the present invention is notlimited to such a flow rate ratio or volume ratios, and otherappropriate flow rate ratios and volume ratios would be readily apparentto one skilled in the art.

The emulsion is combined with a first extraction liquid in a secondstatic mixer. In a preferred embodiment, the first extraction liquid ispumped at a first rate into the emulsion flowing out of the first staticmixer to form a first combined stream. The first combined stream is thenallowed to flow through the second static mixer. The volume ratio of theemulsion to the first extraction liquid can be approximately 1:1,although it should be readily apparent to one skilled in the art thatother volume ratios can be used. In one embodiment, the second staticmixer comprises a plurality of individual static mixers configured toprovide a plurality of parallel flow streams. In a particularlypreferred embodiment, the plurality of individual static mixers is two.However, it should be understood by one skilled in the art that thepresent invention is not limited to the use of two individual staticmixers in such a configuration, and other appropriate numbers ofindividual static mixers would be readily apparent to one skilled in theart.

The outflow of the second static mixer is combined with a secondextraction liquid. The second extraction liquid can be the same as, ordifferent from, the first extraction liquid. The second extractionliquid can be the same as, or different from, the second phase.Similarly, the first extraction liquid can be the same as, or differentfrom, the second phase.

In one embodiment of the present invention, the outflow of the secondstatic mixer flows into a vessel that contains the second extractionliquid. In an alternate embodiment, the outflow of the second staticmixer flows into the vessel, and the second extraction liquid is addedto the vessel. The second extraction liquid can be added to the vesseleither while the outflow of the second static mixer is flowing into thevessel, or after the outflow of the second static mixer has completedflowing into the vessel.

In a further embodiment of the present invention, the outflow of thesecond static mixer is combined with the second extraction liquid in athird static mixer. Preferably, the second extraction liquid is pumpedat a second rate into the outflow of the second static mixer to form asecond combined stream, and the second combined stream is allowed toflow through the third static mixer. In one embodiment, the second rateof pumping the second extraction liquid is greater than the first rateof pumping the first extraction liquid. However, the present inventionis not limited to such pumping rates, and suitable pumping rates wouldbe readily apparent to one skilled in the art.

The third static mixer can be an individual static mixer, a plurality ofindividual static mixers arranged in series, or a plurality ofindividual static mixers configured to provide a plurality of parallelflow streams. The outflow of the third static mixer flows into a vessel.The vessel can be empty prior to allowing the outflow of the thirdstatic mixer to flow therein. Alternatively, the vessel can contain anextraction liquid or other type of quench solution prior to allowing theoutflow of the third static mixer to flow therein.

An alternate method for preparing microparticles in accordance with thepresent invention will now be described. A first phase, comprising anactive agent and a polymer, is prepared. A second phase is prepared, andcombined with the first phase in a first static mixer to form anemulsion, the emulsion forming an outflow of the first static mixer.Suitable methods and processes for preparing the first and secondphases, and for combining in the first static mixer, have been describedabove and will not be repeated here for brevity.

The outflow of the first static mixer is combined with a first portionof a starting volume of an extraction liquid in a second static mixer toform an outflow of the second static mixer. The extraction liquid can bethe same as, or different from, the second phase. The second staticmixer can be an individual static mixer, a plurality of individualstatic mixers arranged in series, or a plurality of individual staticmixers configured to provide a plurality of parallel flow streams.

The outflow of the second static mixer is divided to form at least twoflow streams. Each of the at least two flow streams flows through aseparate third static mixer. The separate third static mixer can be anindividual static mixer, one of a plurality of individual static mixersarranged in series, or one of a plurality of individual static mixersconfigured to provide a plurality of parallel flow streams.

The at least two flow streams are combined with a second portion of theextraction liquid. In an alternate embodiment of the present invention,the at least two flow streams are combined with another extractionliquid different from the first portion of the extraction liquid. Thisother extraction liquid can be the same as, or different from, thesecond phase.

In one embodiment of the present invention, the at least two flowstreams are combined with the second portion of the extraction liquid byallowing the at least two flow streams to flow into a vessel containingthe second portion of the extraction liquid. In an alternate embodiment,the at least two flow streams are combined with the second portion ofthe extraction liquid in a fourth static mixer. The outflow of thefourth static mixer can then flow into a vessel. In a particularlypreferred embodiment, the at least two flow streams are combined withthe second portion of the extraction liquid in a fourth static mixer,and this combining step is continued until the starting volume of theextraction liquid is depleted.

Microparticles of the Present Invention

The microparticles prepared by the process of the present inventionpreferably comprise a polymeric binder, but it should be understood byone skilled in the art that the present invention is not limited topreparation of microparticles comprising a polymeric binder. Suitablepolymeric binder materials include poly(glycolic acid), poly-d,l-lacticacid, poly-l-lactic acid, copolymers of the foregoing, poly(aliphaticcarboxylic acids), copolyoxalates, polycaprolactone, polydioxanone,poly(ortho carbonates), poly(acetals), poly(lactic acid-caprolactone),polyorthoesters, poly(glycolic acid-caprolactone), polyanhydrides,polyphosphazines, albumin, casein, and waxes. Poly(d,l-lactic-co-glycolic acid) is commercially available from Alkermes,Inc. (Blue Ash, Ohio). A suitable product commercially available fromAlkermes, Inc. is a 50:50 poly(d,l-lactic-co-glycolic acid) known asMEDISORB® 5050 DL. This product has a mole percent composition of 50%lactide and 50% glycolide. Other suitable commercially availableproducts are MEDISORB® 6535 DL, 7525 DL, 8515 DL and poly(d,l-lacticacid) (100 DL). Poly(lactide-co-glycolides) are also commerciallyavailable from Boehringer Ingelheim (Germany) under its Resomer® mark,e.g., PLGA 50:50 (Resomer® RG 502), PLGA 75:25 (Resomer® RG 752) andd,l-PLA (Resomer® RG 206), and from Birmingham Polymers (Birmingham,Ala.). These copolymers are available in a wide range of molecularweights and ratios of lactic acid to glycolic acid.

One type of microparticle suitable for preparation by the presentinvention is a sustained-release microparticle that is biodegradable.However, it should be understood by one skilled in the art that thepresent invention is not limited to biodegradable or other types ofsustained-release microparticles. As would be apparent to one skilled inthe art, the molecular weight of the polymeric binder material forbiodegradable microparticles is of some importance. The molecular weightshould be high enough to permit the formation of satisfactory polymercoatings, i.e., the polymer should be a good film former. Usually, asatisfactory molecular weight is in the range of 5,000 to 500,000daltons, preferably about 150,000 daltons. However, since the propertiesof the film are also partially dependent on the particular polymericbinder material being used, it is very difficult to specify anappropriate molecular weight range for all polymers. The molecularweight of the polymer is also important from the point of view of itsinfluence upon the biodegradation rate of the polymer. For a diffusionalmechanism of drug release, the polymer should remain intact until all ofthe drug is released from the microparticles and then degrade. The drugcan also be released from the microparticles as the polymeric binderbioerodes. By an appropriate selection of polymeric materials amicroparticle formulation can be made in which the resultingmicroparticles exhibit both diffusional release and biodegradationrelease properties. This is useful in according multiphasic releasepatterns.

The microparticles prepared in accordance with the present invention mayinclude an active agent or other type of substance that is released fromthe microparticles into the host. Such active agents can include1,2-benzazoles, more particularly, 3-piperidinyl-substituted1,2-benzisoxazoles and 1,2-benzisothiazoles. The most preferred activeagents of this kind are3-[2-[4-(6-fluoro-1,2-benzisoxazol-3-yl)-1-piperidinyl]ethyl]-6,7,8,9-tetrahydro-2-methyl-4H-pyrido[1,2-a]pyrimidin-4-one(“risperidone”) and3-[2-[4-(6-fluro-1,2-benzisoxazol-3-yl)-1-piperidinyl]ethyl]-6,7,8,9-tetrahydro-9-hydroxy-2-methyl-4H-pyrido[1,2-a]pyrimidin-4-one(“9-hydroxyrisperidone”) and the pharmaceutically acceptable saltsthereof. Risperidone (which term, as used herein, is intended to includeits pharmaceutically acceptable salts) is most preferred. Risperidonecan be prepared in accordance with the teachings of U.S. Pat. No.4,804,663, the entirety of which is incorporated herein by reference.9-hydroxyrisperidone can be prepared in accordance with the teachings ofU.S. Pat. No. 5,158,952, the entirety of which is incorporated herein byreference.

Other biologically active agents include non-steroidal antifertilityagents; parasympathomimetic agents; psychotherapeutic agents; majortranquilizers such as chlorpromazine HCl, clozapine, mesoridazine,metiapine, reserpine, thioridazine and the like; minor tranquilizerssuch as chlordiazepoxide, diazepam meprobamate, temazepam and the like;rhinological decongestants; sedative-hypnotics such as codeine,phenobarbital, sodium pentobarbital, sodium secobarbital and the like;steroids such as testosterone and tesosterone propionate; sulfonamides;sympathomimetic agents; vaccines; vitamins and nutrients such as theessential amino acids; essential fats and the like; antimalarials such4-aminoquinolines, 8-aminoquinolines, pyrimethamine and the like,anti-migraine agents such as mazindol, phentermine and the like;anti-Parkinson agents such as L-dopa; anti-spasmodics such as atropine,methscopolamine bromide and the like; antispasmodics and anticholinergicagents such as bile therapy, digestants, enzymes and the like;antitussives such as dextromethorphan, noscapine and the like;bronchodilators; cardiovascular agents such as anti-hypertensivecompounds, Rauwolfia alkaloids, coronary vasodilators, nitroglycerin,organic nitrates, pentaerythritotetranitrate and the like; electrolytereplacements such as potassium chloride; ergotalkaloids such asergotamine with and without caffeine, hydrogenated ergot alkaloids,dihydroergocristine methanesulfate, dihydroergocomine methanesulfonate,dihydroergokroyptine methanesulfate and combinations thereof; alkaloidssuch as atropine sulfate, Belladonna, hyoscine hydrobromide and thelike; analgetics, narcotics such as codeine, dihydrocodienone,meperidine, morphine and the like; non-narcotics such as salicylates,aspirin, acetaminophen, d-propoxyphene and the like; antibiotics such assalicylates, aspirin, acetaminophen, d-propoxyphene and the like;antibiotics such as the cephalosporins, chloranphenical, gentamicin,Kanamycin A, Kanamycin B, the penicillins, ampicillin, streptomycin A,antimycin A, chloropamtheniol, metromidazole, oxytetracycline penicillinG, the tetracylines, and the like, anti-cancer agents; anti-convulsantssuch as mephenytoin, phenobarbital, trimethadione; anti-emetics such asthiethylperazine; antihistamines such as chlorophinazine,dimenhydrinate, diphenhydramine, perphenazine, tripelennamine and thelike; anti-inflammatory agents such as hormonal agents, hydrocortisone,prednisolone, prednisone, non-hormonal agents, allopurinol, aspirin,indomethacin, phenylbutazone and the like; prostaglandins; cytotoxicdrugs such as thiotepa; chlorambucil, cyclophosphamide, melphalan,nitrogen mustard, methotrexate and the like; antigens of suchmicroorganisms as Neisseria gonorrhea, Mycobacterium tuberculosis,Herpes virus (homonis, types 1 and 2), Candida albicans, Candidatropicalis, Trichomonas vaginalis, Haemophilus vaginalis, Group BStreptococcus ecoli, Mycoplasma hominis, Haemophilus ducreyi, Granulomainguinale, Lymphopathia venereum, Treponema pallidum, Brucella abortus,Brucella melitensis, Brucella suis, Brucella canis, Campylobacter fetus,Campylobacter fetus intestinalis, Leptospira pomona, Listeriamonocytogenes, Brucella ovis, Equine herpes virus 1, Equine arteritisvirus, IBR-IBP virus, BVD-MB virus, Chliamydia psittaci, Trichomonasfoetus, Toxoplasma gondii, Escherichia coli, Actinobacillus equuli,Salmonella abortus ovis, Salmonella abortus equi, Pseudomonasaeruginosa, Corynebacterium equi, Corynebacterium pyogenes,Actinobacillus seminis, Mycoplasma bovigenitalium, Aspergillusfumigatus, Absidia ramosa, Trypanosoma equiperdum, Babesia caballi,Clostridium tetani, and the like; antibodies that counteract the abovemicroorganisms; and enzymes such as ribonuclease, neuramidinase,trypsin, glycogen phosphorylase, sperm lactic dehydrogenase, spermhyaluronidase, adenosinetriphosphatase, alkaline phosphatase, alkalinephosphatase. esterase, amino peptidase, trypsin, chymotrypsin, amylase,muramidase, acrosomal proteinase, diesterase, glutamic aciddehydrogenase, succinic acid dehydrogenase, beta-glycophosphatase,lipase, ATP-ase alpha-peptate gamma-glutamylotranspeptidase,sterol-3-beta-ol-dehydrogenase, and DPN-di-aprorasse.

Other suitable active agents include estrogens such as diethylstilbestrol, 17-beta-estradiol, estrone, ethinyl estradiol, mestranol,and the like; progestins such as norethindrone, norgestryl, ethynodioldiacetate, lynestrenol, medroxyprogesterone acetate, dimesthisterone,megestrol acetate, chlormadinone acetate, norgestimate, norethisterone,ethisterone, melengestrol, norethynodrel and the like; and thespermicidal compounds such as nonylphenoxypolyoxyethylene glycol,benzethonium chloride, chlorindanol and the like.

Still other suitable active agents include antifungals, antivirals,anticoagulants, anticonvulsants, antidepressants, antihistamines,hormones, vitamins and minerals, cardiovascular agents, peptides andproteins, nucleic acids, immunological agents, antigens of suchbacterial organisms as Streptococcus pneumoniae, Haemophilus influenzae,Staphylococcus aureus, Streptococcus pyogenes, Corynebacteriumdiphtheriae, Bacillus anthracis, Clostridium tetani, Clostridiumbotulinum, Clostridium perfringens, Streptococcus mutans, Salmonellatyphi, Haemophilus parainfluenzae, Bordetella pertussis, Francisellatularensis, Yersinia pestis, Vibrio cholerae, Legionella pneumophila,Mycobacterium leprae, Leptospira interrogans, Borrelia burgdorferi,Campylobacter jejuni, antigens of such viruses as smallpox, influenza Aand B, respiratory syncytial, parainfluenza, measles, HIV,varicella-zoster, herpes simplex 1 and 2, cytomegalovirus, Epstein-Barr,rotavirus, rhinovirus, adenovirus, papillomavirus, poliovirus, mumps,rabies, rubella, coxsackieviruses, equine encephalitis, Japaneseencephalitis, yellow fever, Rift Valley fever, lymphocyticchoriomeningitis, hepatitis B, antigens of such fungal protozoan, andparasitic organisms such as Cryptococcus neoformans, Histoplasmacapsulatum, Candida albicans, Candida tropicalis, Nocardia asteroides,Rickettsia ricketsii, Rickettsia typhi, Mycoplasma pneumoniae, Chlamydiapsittaci, Chlamydia trachomatis, Plasmodium falciparum, Trypanosomabrucei, Entamoeba histolytica, Toxoplasma gondii, Trichomonas vaginalis,Schistosoma mansoni. These antigens may be in the form of whole killedorganisms, peptides, proteins, glycoproteins, carbohydrates, orcombinations thereof.

Still other macromolecular bioactive agents that may be chosen forincorporation include, but are not limited to, blood clotting factors,hemopoietic factors, cytokines, interleukins, colony stimulatingfactors, growth factors, and analogs and fragments thereof.

The microparticles can be mixed by size or by type. However, it shouldbe understood that the present invention is not limited to the use ofbiodegradable or other types of microparticles that contain an activeagent. In one embodiment, the microparticles are mixed in a manner thatprovides for the delivery of active agent to the patient in amultiphasic manner and/or in a manner that provides different activeagents to the patient at different times, or a mixture of active agentsat the same time. For example, secondary antibiotics, vaccines, or anydesired active agent, either in microparticle form or in conventional,unencapsulated form can be blended with a primary active agent andprovided to the patient.

Apparatus

Turning now to FIG. 1, one embodiment of the apparatus of the presentinvention is shown (system 100). A first phase 110 and a second phase120 are pumped via a pump 112 and a pump 122, respectively, into a firststatic mixer 130 to form an emulsion. The first phase preferablycomprises an active agent and a polymer, and is preferably in the formof a solution. The second phase is preferably an aqueous solution thatfunctions as the continuous phase of the emulsion.

A static or motionless mixer consists of a conduit or tube in which isreceived a number of static mixing elements. Static mixers provideuniform mixing in a relatively short length of conduit, and in arelatively short period of time. With static mixers, the fluid movesthrough the mixer, rather than some part of the mixer, such as a blade,moving through the fluid. Flow through one type of static mixer isillustrated in FIG. 3. A pump (not shown) introduces a stream of one ormore fluids into a static mixer 10, as shown generally at 1. The streamis split and forced to opposite outside walls, as shown generally at 2.A vortex is created axial to the centerline of static mixer 10, as showngenerally at 3. The vortex is sheared and the process recurs, but withthe opposite rotation, as shown generally at 4. Theclockwise/counterclockwise motion ensures a homogeneous product.

One example of a static mixer is shown in FIG. 4. Static mixer 10includes a number of stationary or static mixing elements 14 arranged ina series within a conduit or pipe 12. The number of static mixingelements can range from 4 to 32 or more. Conduit 12 is circular incross-section and open at opposite ends 18 and 20 for introducing andwithdrawing fluids. Mixing element 14 comprises segments 42. Eachsegment 42 consists of a plurality of generally flat plates or vanes 44.The two substantially identical segments 42 are preferably axiallystaggered with respect to each other. A static mixer as shown in FIG. 4is more fully described in U.S. Pat. No. 4,511,258, the entirety ofwhich is incorporated herein by reference.

The emulsion is combined with a first extraction liquid 150, pumped viaa pump 152, in a second static mixer 140. Static mixer 140 functions asa blending static mixer to blend the emulsion and the first extractionliquid. The outflow of second static mixer 140 flows into a vessel 160.In one embodiment of the present invention, vessel 160 contains a secondextraction liquid. The second extraction liquid can be the same as, ordifferent from, the first extraction liquid. In further embodiments ofthe invention, second phase 120 can be used as the first extractionliquid and/or the second extraction liquid.

In another embodiment of the present invention, the outflow of secondstatic mixer 140 flows into vessel 160, and the second extraction liquidis added to vessel 160. The second extraction liquid can be added tovessel 160 either while the outflow of second static mixer 140 isflowing into vessel 160, or after the outflow of second static mixer 140has completed flowing into vessel 160.

Static mixer 140 is shown in FIG. 1 as an individual static mixer.Alternatively, static mixer 140 could be configured as a manifold thatincludes a plurality of individual static mixers arranged in parallel toprovide a plurality of parallel flow streams, as shown, for example, bymanifold 240 illustrated in FIG. 2. Alternatively, static mixer 140could be configured as a plurality of individual static mixers arrangedin series. Similarly, static mixer 130 could also be configured as amanifold that includes a plurality of individual static mixersarranged-in parallel, or as a series of individual static mixers. Itshould be understood by one skilled in the art that the presentinvention is not limited to the use of an individual static mixer forany of the elements depicted as individual static mixers in the Figures.As would be readily apparent to one skilled in the art, a plurality ofindividual static mixers arranged in series could be used, or a manifoldcontaining a plurality of individual static mixers arranged in parallelto -provide a plurality of parallel flow streams could also be used.

Another embodiment of the invention is shown in FIG. 2 (system 200). Afirst phase 210 and a second phase 220 are pumped via a pump 212 and apump 222, respectively, into a first static mixer 230 to form anemulsion. The first phase preferably comprises an active agent and apolymer, and is preferably in the form of a solution. The second phaseis preferably an aqueous solution that functions as the continuous phaseof the emulsion.

The emulsion is combined with a first portion of an extraction liquid250, pumped via a pump 252, in a static mixer 235. Static mixer 235functions as a blending static mixer to blend the emulsion and the firstextraction liquid. The outflow of static mixer 235 is divided into aplurality of flow streams that flow into a manifold 240. Manifold 240includes a plurality of individual static mixers 242 configured in aparallel arrangement that provides a plurality of parallel flow streams.Although FIG. 2 shows three individual and separate static mixers 242 inmanifold 240, it should be readily apparent to one skilled in the artthat manifold 240 can be configured with more, or less, individualstatic mixers 242. In a preferred embodiment, manifold 240 includes twoindividual static mixers 242, and the outflow of static mixer 235 isdivided into two flow streams, each of the two flow streams flowingthrough one of the two individual static mixers.

The outflows of individual static mixers 242 are combined to form theoutflow of manifold 240. The outflow of manifold 240 is combined with asecond portion of extraction liquid 250, pumped via a pump 254, inanother static mixer 270. In an alternate embodiment of the presentinvention, manifold 240 is replaced with a single static mixer locatedbetween static mixer 235 and static mixer 270. In yet another alternateembodiment, manifold 240 is replaced with a plurality of individualstatic mixers arranged in series. As would be readily apparent to oneskilled in the art, static mixers 230, 235, and 270 depicted in FIG. 2as individual static mixers could be replaced with a plurality ofindividual static mixers arranged in series, or with a manifoldcontaining a plurality of individual static mixers arranged in parallel.

In one embodiment, pump 254 is configured to operate at a flow rategreater than a flow rate of pump 252. It should be understood that thepresent invention is not limited to such a flow rate configuration, andother suitable flow rates would be readily apparent to one skilled inthe art.

The outflow of manifold 240 is combined with extraction liquid 250 instatic mixer 270, and this combining is repeated until the startingvolume of extraction liquid 250 is depleted. Once the starting volume ofextraction liquid 250 is depleted, the outflow of static mixer 270 flowsinto a vessel 260 that is preferably initially empty, i.e., does notcontain any extraction liquid. In this manner, all of extraction liquid250 is introduced into the processing stream, and combined with theemulsion in one of the static mixers.

In system 200 as shown in FIG. 2, extraction liquid 250 is introducedinto the processing stream at two different points via pumps 252 and254. In an alternate embodiment of system 200, one type of extractionliquid could be introduced via pump 252, and a different type ofextraction liquid could be introduced via pump 254. In a furtherembodiment, second phase 220 could be used as one or both of theextraction liquids introduced via pumps 252 and 254.

Alternatively, system 200 could be modified to eliminate static mixer270 so that the outflow of manifold 240 flows into vessel 260 thatcontains the second portion of extraction liquid 250. System 200 couldalso be modified to add additional static mixers 270 in which additionalportions of extraction liquid 250, or other different type of extractionliquid, are combined with the flow stream.

Conclusion

While various embodiments of the present invention have been describedabove, it should be understood that they have been presented by way ofexample only, and not limitation. The present invention is not limitedto the preparation of controlled release microparticles, nor is itlimited to a particular active agent, polymer or solvent, nor is thepresent invention limited to a particular scale or batch size. Thus, thebreadth and scope of the present invention should not be limited by anyof the above-described exemplary embodiments, but should be defined onlyin accordance with the following claims and their equivalents.

What is claimed is:
 1. A method of preparing microparticles, comprising:preparing a first phase, the first phase comprising an active agent, apolymer, and a solvent; preparing a continuous second phase; combiningthe first phase and the second phase in a first static mixer to form anemulsion; combining the emulsion and a first extraction liquid forextracting solvent from the emulsion in a manifold, wherein the manifoldcomprises a plurality of individual static mixers configured to form aplurality of parallel flow streams, each of the plurality of parallelflow streams comprising at least one of the plurality of individualstatic mixers; and combining an outflow of the manifold with a secondextraction liquid to extract solvent from the emulsion.
 2. A system forpreparing microparticles, comprising: a first pump; a second pump; afirst static mixer in fluid communication with said first pump and withsaid second pump, wherein said first pump is configured to pump anorganic phase into said first static mixer, and said second pump isconfigured to pump a continuous phase into said first static mixer; amanifold in fluid communication with said first static mixer, saidmanifold comprising a plurality of individual static mixers configuredto form a plurality of parallel flow streams, each of said plurality ofparallel flow streams comprising at least one of said plurality ofindividual static mixers; a third pump in fluid communication with saidmanifold, wherein said third pump is configured to pump an extractionliquid; and a second static mixer in fluid communication with saidmanifold, wherein an outflow of said first static mixer and theextraction liquid flow through said manifold and through said pluralityof parallel flow streams and then through said second static mixer.